Reinforcement system

ABSTRACT

A novel reinforcement system for maximizing tensile strength and modulus of elasticity per ply for composite systems has one or more pockets with a first pocket edge, a second pocket edge, a pocket front surface, and a pocket rear surface. The pocket front surface and the pocket rear surface each have a pocket cross-stitch that perpendicularly traverses the pocket. The pocket traverses the fabric parallel and adjacent to the first fabric edge and the second fabric edge in a warp, or 0 degree, or x-axis direction. The pockets contain one or more fiber tows with a plurality of filaments in a stack.

CROSS REFERENCE

This application claims priority to U.S. Non-Provisional applicationSer. No. 14/186,571 filed Feb. 21, 2014 as a continuation, claimspriority to U.S. Non-Provisional application Ser. No. 13/333,910 filedDec. 21, 2011 now U.S. Pat. No. 8,696,849, and to U.S. provisionalapplication Ser. No. 61/425,949 filed Dec. 22, 2010, thespecification(s) of which is/are incorporated herein by reference in itsentirety.

BACKGROUND OF THE INVENTION

Carbon fiber reinforced polymer is a strong and lightweight system thatcan be used as a material of construction or a system of repair with itsorigins in the late 1950s. Carbon fiber consists mostly of carbon atomsbonded together in crystals that are basically aligned parallel to forma long axis giving the fiber very high strength to weight properties.Carbon fibers are usually combined with other materials, such aspolymers, to form a composite. Carbon fiber composite materials combinethe very high strength-to-weight properties of the carbon fiber with aversatile polymer matrix to utilize the unique properties in fabricationand repair applications.

SUMMARY

The present invention features a novel reinforcement system formaximizing tensile strength and modulus of elasticity per ply forcomposite systems.

In some embodiments, the fabric has one or more pockets with a firstpocket edge, a second pocket edge, a pocket front surface, and a pocketrear surface. In some embodiments, the pocket front surface and thepocket rear surface each has a pocket cross-stitch that perpendicularlytraverses the pocket. In some embodiments, the pocket traverses thefabric parallel and adjacent to the first fabric edge and the secondfabric edge in a warp, or 0 degree, or x-axis direction. In someembodiments, the pocket contains one or more fiber tows with a pluralityof filaments in a stack.

Any feature or combination of features described herein are includedwithin the scope of the present invention provided that the featuresincluded in any such combination are not mutually inconsistent as willbe apparent from the context, this specification, and the knowledge ofone of ordinary skill in the art. Additional advantages and aspects ofthe present invention are apparent in the following detailed descriptionand claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of the fabric of the present invention.

FIG. 2 is a close-up view of the reinforcement system of the presentinvention.

FIG. 3 is a close-up view of the reinforcement system of the presentinvention.

FIG. 4 is a cross-sectional view of the reinforcement system of thepresent invention.

FIG. 5 is a close-up view of the reinforcement system of the presentinvention.

FIG. 6 is a perspective view of the fabric of the present invention.

FIG. 7 is a close-up view of the reinforcement system of the presentinvention.

FIG. 8 is a perspective cross-sectional view of the reinforcement systemof the present invention.

FIG. 9 is a perspective cross-sectional view of the reinforcement systemof the present invention.

FIG. 10 is a view of the structural repair and reinforcement system ofthe present invention.

FIG. 11A-11C is a perspective view of embodiments of the housing matrix.

FIG. 12A-12M is a perspective view of embodiments of the channel.

DESCRIPTION OF PREFERRED EMBODIMENTS

Following is a list of elements corresponding to a particular elementreferred to herein:

100 Reinforcement fabric

210 First fabric edge seam

220 First fabric edge

230 Second fabric edge seam

240 Second fabric edge

300 Pocket

310 First pocket seam

320 First pocket edge

330 Second pocket seam

340 Second pocket edge

350 Pocket front surface

360 Pocket rear surface

370 Stitching

380 Pocket cross-stitch

382 Stitch first end

384 Stitch second end

400 Fiber tow

410 Filament

420 Stack

500 X-axis (0 degrees)

510 Y-axis or 90 degrees

520 Z-axis

600 Polymer resin composition

610 Resin component

620 Activation component

630 Modified vinyl ester resin composition

700 Substrate

710 Low-viscosity epoxy primer

720 Roller

730 Packaging

740 Open area

800 Structural repair and reinforcement system

810 Preimpregnated structural repair and reinforcement system

820 Reinforcement system

900 Reinforcement fiber housing matrix

910 Channel

920 First channel side

930 Second channel side

950 Sub-channel

Novel Reinforcement System

Referring now to FIG. 1-12M, the present invention features a novelreinforcement fabric (100) system for maximizing tensile strength andmodulus of elasticity per ply for composite systems. In someembodiments, this is measured in pounds/inch/width.

In some embodiments, the fabric (100) has a first fabric edge seam (210)located on a first fabric edge (220), and a second fabric edge seam(230) located on a second fabric edge (240). In some embodiments, thefirst fabric edge seam (210) traverses and binds the fabric (100)parallel and adjacent to the first fabric edge (220), and the secondfabric edge seam (230) traverses and binds the fabric (100) parallel toand adjacent to the second fabric edge (240). In some embodiments, thefirst fabric edge (220) and second fabric edge (240) traverse the fabric(100) in the direction of an X-axis (0 degrees) (500).

In some embodiments, the fabric (100) has a pocket (300) with a firstpocket edge (320), a second pocket edge (340), a pocket front surface(350), and a pocket rear surface (360). In some embodiments, the pocket(300) has a first pocket seam (310) located on the first pocket edge(320). In some embodiments, the first pocket seam (310) has a stitching(370) in a plane defined by the X-axis (0 degrees) (500) and a Z-axis(520) alternatingly attaching the pocket front surface (350) to thepocket rear surface (360) via the stitching (370). In some embodiments,the first pocket seam (310) traverses the fabric (100) parallel andadjacent to the first pocket edge (320).

In some embodiments, the pocket (300) has a second pocket seam (330)located on the second pocket edge (340). In some embodiments, the secondpocket seam (330) has a stitching (370) in a plane defined by the X-axis(0 degrees) (500) and the Z-axis (520) alternatingly attaching thepocket front surface (350) to the pocket rear surface (360) via thestitching (370). In some embodiments, the second pocket seam (330)traverses the fabric (100) parallel and adjacent to the second pocketedge (340).

In some embodiments, the pocket front surface (350) has a pocketcross-stitch (380) that perpendicularly traverses the pocket (300) withrespect to the first pocket seam (310) and the second pocket seam (330)in a direction of a Y-axis or 90 degrees (510). In some embodiments, thepocket rear surface (360) has a pocket cross-stitch (380) thatperpendicularly traverses the pocket (300) with respect to the firstpocket seam (310) and the second pocket seam (330) in the direction ofthe Y-axis or 90 degrees (510).

In some embodiments, the pocket cross-stitch (380) has a stitch firstend (382) attached to the first pocket seam (310) and a stitch secondend (384) attached to the second pocket seam (330).

In some embodiments, the pocket (300) traverses the fabric (100)parallel and adjacent to the first fabric edge (220) and the secondfabric edge (240) in a warp, or 0 degree, or X-axis (500) direction.

In some embodiments, the fabric (100) has a fiber tow (400) with aplurality of filaments (410) located in a stack (420). In someembodiments, the fiber tow (400) is located lengthways in the directionof the X-axis (0 degrees) (500) in the pocket (300).

In some embodiments, the filament (410) is constructed from a materialselected from a group consisting of: polyethylene, glass, basalt,aramid, and carbon.

In some embodiments, a plurality of pockets (300) is located in parallelin a series. In some embodiments, a first pocket edge (320) of a firstpocket (300) is joined to a second pocket edge (340) of a second pocket(300). In some embodiments, a plurality of pockets (300) is joined inparallel in a series at the first pocket edge (320) and the secondpocket edge (340) of each pocket (300) in the series.

In some embodiments, the pocket (300) is located in a weft, or 90degree, or Y-axis (510) direction with respect to the first fabric edge(220) and the second fabric edge (240).

In some embodiments, the fiber tow (400) has from about 1 filament (410)to about 3,000 filaments (410). In some embodiments, the fiber tow (400)has from about 3,000 filaments (410) to about 6,000 filaments (410). Insome embodiments, the fiber tow (400) has from about 6,000 filaments(410) to about 12,000 filaments (410). In some embodiments, the fibertow (400) has from about 12,000 filaments (410) to about 50,000filaments (410). In some embodiments, the fiber tow (400) has more thanabout 50,000 filaments (410). In some embodiments, the fiber tow (400)has more than about 400,000 filaments (410).

In some embodiments, the cross-sectional area of the stacks (420) isabout 50% to 70% of the cross-sectional area of the pocket (300). Insome embodiments, the cross-sectional area of the stacks (420) is about70% to 85% of the cross-sectional area of the pocket (300). In someembodiments, the cross-sectional area of the stacks (420) is about 85%to 99.5% of the cross-sectional area of the pocket (300).

In some embodiments, the volume of the stacks (420) in the pocket (300)is about 50% to 70% of the volume of the pocket (300). In someembodiments, the volume of the stacks (420) in the pocket (300) is about70% to 85% of the volume of the pocket (300). In some embodiments, thevolume of the stacks (420) in the pocket (300) is about 85% to 99.5% ofthe volume of the pocket (300).

In some embodiments, the fiber tow (400) has a plurality ofnon-interlaced filaments (410). In some embodiments, the fiber tow (400)has a plurality of interlaced filaments (410). In some embodiments, thefiber tow (400) has a plurality of non-twisted filaments (410). In someembodiments, the fiber tow (400) has a plurality of twisted filaments(410).

In some embodiments, the fiber tow (400) has a plurality of filaments(410) located one upon another forming a generally ellipticalcross-section of the fiber tow (400) located in the pocket (300).

In some embodiments, the pocket front surface (350) has an open area(740) greater than 50%. In some embodiments, the open area (740) has anarea wherein filaments (410) are exposed between a plurality of pocketcross-stitches (380) of the pocket front surface (350).

In some embodiments, the pocket rear surface (360) has an open area(740) greater than 50%. In some embodiments, the open area (740) has anarea wherein filaments (410) are exposed between a plurality of pocketcross-stitches (380) of the pocket rear surface (360).

In some embodiments, the fabric (100) is electrically conductive. Insome embodiments, the fabric (100) contains a heating element. In someembodiments, the fabric (100) contains a resistance wire, ribbon, orstrip. In some embodiments, the fabric (100) is attached to a regulatedpower supply. In some embodiments, the fabric (100) is operativelyattached to a regulated power supply to power the heating element of thefabric (100) to a controlled temperature using Joule heating. In someembodiments, the heated fabric (100) can be used to activate a modifiedvinyl ester resin composition (630). In some embodiments, the heatedfabric (100) can be used to activate a resin composition.

In some embodiments, the thread used for the first fabric edge seam(210), second fabric edge seam (230), first pocket seam (310), secondpocket seam (330), stitching (370), and pocket cross-stitch (380) aremanufactured from a polyester.

In some embodiments, Low-viscosity epoxy primer (710) measures betweenabout 200 and 800 centipoise (cP).

In some embodiments, the roller (720) is a nap roller (720).

In some embodiments, air-tight packaging (730) includes vacuum sealedpackaging (730).

Structural Repair and Reinforcement System

In some embodiments, a structural repair and reinforcement system (800)for maximizing tensile strength and modulus of elasticity per ply viacomposite technology has a ply of reinforcement fabric (100). In someembodiments, the fabric (100) has a first fabric edge seam (210) locatedon a first fabric edge (220), and a second fabric edge seam (230)located on a second fabric edge (240). In some embodiments, the firstfabric edge seam (210) traverses and binds the fabric (100) parallel andadjacent to the first fabric edge (220), and the second fabric edge seam(230) traverses and binds the fabric (100) parallel to and adjacent tothe second fabric edge (240). In some embodiments, the first fabric edge(220) and second fabric edge (240) traverse the fabric (100) in thedirection of an X-axis (0 degrees) (500).

In some embodiments, the fabric (100) has a pocket (300) with a firstpocket edge (320), a second pocket edge (340), a pocket front surface(350), and a pocket rear surface (360). In some embodiments, the pocket(300) has a first pocket seam (310) located on the first pocket edge(320). In some embodiments, the first pocket seam (310) has a stitching(370) in a plane defined by the X-axis (0 degrees) (500) and a Z-axis(520) alternatingly attaching the pocket front surface (350) to thepocket rear surface (360) via the stitching (370). In some embodiments,the first pocket seam (310) traverses the fabric (100) parallel andadjacent to the first pocket edge (320).

In some embodiments, the pocket (300) has a second pocket seam (330)located on the second pocket edge (340). In some embodiments, the secondpocket seam (330) has a stitching (370) in a plane defined by the X-axis(0 degrees) (500) and the Z-axis (520) alternatingly attaching thepocket front surface (350) to the pocket rear surface (360) via thestitching (370). In some embodiments, the second pocket seam (330)traverses the fabric (100) parallel and adjacent to the second pocketedge (340).

In some embodiments, the pocket front surface (350) has a pocketcross-stitch (380) that perpendicularly traverses the pocket (300) withrespect to the first pocket seam (310) and the second pocket seam (330)in a direction of a Y-axis or 90 degrees (510). In some embodiments, thepocket rear surface (360) has a pocket cross-stitch (380) thatperpendicularly traverses the pocket (300) with respect to the firstpocket seam (310) and the second pocket seam (330) in the direction ofthe Y-axis or 90 degrees (510).

In some embodiments, the pocket cross-stitch (380) has a stitch firstend (382) attached to the first pocket seam (310) and a stitch secondend (384) attached to the second pocket seam (330).

In some embodiments, the pocket (300) traverses the fabric (100)parallel and adjacent to the first fabric edge (220) and the secondfabric edge (240) in a warp, or 0 degree, or X-axis (500) direction.

In some embodiments, the pocket (300) has a fiber tow (400) with aplurality of filaments (410) located in a stack (420). In someembodiments, the fiber tow (400) is located lengthways in the directionof the X-axis (0 degrees) (500) in the pocket (300).

In some embodiments, the filament (410) is constructed from a materialselected from a group consisting of: polyethylene, glass, basalt,aramid, and carbon.

In some embodiments, a plurality of pockets (300) is located in parallelin a series. In some embodiments, a first pocket edge (320) of a firstpocket (300) is joined to a second pocket edge (340) of a second pocket(300). In some embodiments, a plurality of pockets (300) is joined inparallel in a series at the first pocket edge (320) and the secondpocket edge (340) of each pocket (300) in the series.

In some embodiments, a structural repair and reinforcement system (800)for maximizing tensile strength and modulus of elasticity per ply viacomposite technology has a polymer resin composition (600). In someembodiments, the polymer resin composition (600) has a resin component(610) and an activation component (620).

In some embodiments, the structural repair and reinforcement system(800) is stored until installed by an end user.

Structural Repair and Reinforcement System Via Preimpregnated CompositeTechnology

In some embodiments, A preimpregnated structural repair andreinforcement system (810) for maximizing tensile strength and modulusof elasticity per ply via preimpregnated composite technology has a plyof reinforcement fabric (100). In some embodiments, the fabric (100) hasa first fabric edge seam (210) located on a first fabric edge (220), anda second fabric edge seam (230) located on a second fabric edge (240).In some embodiments, the first fabric edge seam (210) traverses andbinds the fabric (100) parallel and adjacent to the first fabric edge(220), and the second fabric edge seam (230) traverses and binds thefabric (100) parallel to and adjacent to the second fabric edge (240).In some embodiments, the first fabric edge (220) and second fabric edge(240) traverse the fabric (100) in the direction of an X-axis (0degrees) (500).

In some embodiments, the reinforcement fabric (100) has a pocket (300)with a first pocket edge (320), a second pocket edge (340), a pocketfront surface (350), and a pocket rear surface (360). In someembodiments, the pocket (300) has a first pocket seam (310) located onthe first pocket edge (320). In some embodiments, the first pocket seam(310) has a stitching (370) in a plane defined by the X-axis (0 degrees)(500) and a Z-axis (520) alternatingly attaching the pocket frontsurface (350) to the pocket rear surface (360) via the stitching (370).In some embodiments, the first pocket seam (310) traverses the fabric(100) parallel and adjacent to the first pocket edge (320).

In some embodiments, the pocket (300) has a second pocket seam (330)located on the second pocket edge (340). In some embodiments, the secondpocket seam (330) has a stitching (370) in a plane defined by the X-axis(0 degrees) (500) and the Z-axis (520) alternatingly attaching thepocket front surface (350) to the pocket rear surface (360) via thestitching (370). In some embodiments, the second pocket seam (330)traverses the fabric (100) parallel and adjacent to the second pocketedge (340).

In some embodiments, the pocket front surface (350) has a pocketcross-stitch (380) that perpendicularly traverses the pocket (300) withrespect to the first pocket seam (310) and the second pocket seam (330)in a direction of a Y-axis or 90 degrees (510). In some embodiments, thepocket rear surface (360) has pocket cross-stitch (380) thatperpendicularly traverses the pocket (300) with respect to the firstpocket seam (310) and the second pocket seam (330) in the direction ofthe Y-axis or 90 degrees (510).

In some embodiments, the pocket cross-stitch (380) has a stitch firstend (382) attached to the first pocket seam (310) and a stitch secondend (384) attached to the second pocket seam (330).

In some embodiments, the pocket (300) traverses the fabric (100)parallel and adjacent to the first fabric edge (220) and the secondfabric edge (240) in a warp, or 0 degree, or X-axis (500) direction.

In some embodiments, the pocket has a fiber tow (400) with a pluralityof filaments (410) located in a stack (420). In some embodiments, thefiber tow (400) is located lengthways in the direction of the X-axis (0degrees) (500) in the pocket (300).

In some embodiments, the filament (410) is constructed from a materialselected from a group consisting of: polyethylene, glass, basalt,aramid, and carbon.

In some embodiments, a preimpregnated structural repair andreinforcement system (810) for maximizing tensile strength and modulusof elasticity per ply via preimpregnated composite technology has amodified vinyl ester resin composition (630) located (or preimpregnated)on the reinforcement fabric (100). In some embodiments, the modifiedvinyl ester resin composition (630) is cross-linked with urethane. Insome embodiments, the modified vinyl ester resin composition (630) iscross-linked with another compound. In some embodiments, a modifiedvinyl ester resin composition is available as DION® 31038-00 that can bepurchased from Reichhold(http://www.reichhold.com/en/composites-products.aspx?cat=Brands&pid=14)as of Dec. 21, 2011.

In some embodiments, the system (810) is stored until installed by anend user. In some embodiments, the system (810) has a shelf life of sixmonths. In some embodiments, the system (810) can be stored in anenvironment having temperatures about ambient. In some embodiments,ambient temperature is less than about 60 degrees Fahrenheit. In someembodiments ambient temperature is about 60 degrees Fahrenheit to about80 degrees Fahrenheit. In some embodiments, ambient temperature is about80 degrees Fahrenheit to about 100 degrees Fahrenheit. In someembodiments, ambient temperature is greater than 100 degrees Fahrenheit.In some embodiments, the system (810) has air-tight packaging (730).

In some embodiments, the system (810) is activated for curing uponraising the temperature of the system (810) to about 275 degreesFahrenheit for about 15 minutes. In some embodiments, the system (810)is activated for curing via exposure to water.

Structural Repair and Reinforcement Method

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viacomposite technology includes obtaining a structural repair andreinforcement system (800).

In some embodiments, the system (800) has a ply of reinforcement fabric(100) having a first fabric edge seam (210) located on a first fabricedge (220), and a second fabric edge seam (230) located on a secondfabric edge (240). In some embodiments, the first fabric edge seam (210)traverses and binds the fabric (100) parallel and adjacent to the firstfabric edge (220), and the second fabric edge seam (230) traverses andbinds the fabric (100) parallel to and adjacent to the second fabricedge (240). In some embodiments, the first fabric edge (220) and secondfabric edge (240) traverse the fabric (100) in the direction of anX-axis (0 degrees) (500).

In some embodiments, the fabric (100) has a pocket (300) with a firstpocket edge (320), a second pocket edge (340), a pocket front surface(350), and a pocket rear surface (360). In some embodiments, the pocket(300) has a first pocket seam (310) located on the first pocket edge(320). In some embodiments, the first pocket seam (310) has a stitching(370) in a plane defined by the X-axis (0 degrees) (500) and a Z-axis(520) alternatingly attaching the pocket front surface (350) to thepocket rear surface (360) via the stitching (370). In some embodiments,the first pocket seam (310) traverses the fabric (100) parallel andadjacent to the first pocket edge (320).

In some embodiments, the pocket (300) has a second pocket seam (330)located on the second pocket edge (340). In some embodiments, the secondpocket seam (330) having a stitching (370) in a plane defined by theX-axis (0 degrees) (500) and the Z-axis (520) alternatingly attachingthe pocket front surface (350) to the pocket rear surface (360) via thestitching (370). In some embodiments, the second pocket seam (330)traverses the fabric (100) parallel and adjacent to the second pocketedge (340).

In some embodiments, the pocket front surface (350) has pocketcross-stitch (380) that perpendicularly traverses the pocket (300) withrespect to the first pocket seam (310) and the second pocket seam (330)in a direction of a Y-axis or 90 degrees (510). In some embodiments, thepocket rear surface (360) has a pocket cross-stitch (380) thatperpendicularly traverses the pocket (300) with respect to the firstpocket seam (310) and the second pocket seam (330) in the direction ofthe Y-axis or 90 degrees (510).

In some embodiments, the pocket cross-stitch (380) has a stitch firstend (382) attached to the first pocket seam (310) and a stitch secondend (384) attached to the second pocket seam (330).

In some embodiments, the pocket (300) traverses the fabric (100)parallel and adjacent to the first fabric edge (220) and the secondfabric edge (240) in a warp, or 0 degree, or X-axis (500) direction.

In some embodiments, the fabric (100) has a fiber tow (400) with aplurality of filaments (410) located in a stack (420). In someembodiments, the fiber tow (400) is located lengthways in the directionof the X-axis (0 degrees) (500) in the pocket (300).

In some embodiments, the filament (410) is constructed from a materialselected from a group consisting of: polyethylene, glass, basalt,aramid, and carbon.

In some embodiments, a plurality of pockets (300) is located in parallelin a series. In some embodiments, a first pocket edge (320) of a firstpocket (300) is joined to a second pocket edge (340) of a second pocket(300). In some embodiments, a plurality of pockets (300) is joined inparallel in a series at the first pocket edge (320) and the secondpocket edge (340) of each pocket (300) in the series.

In some embodiments, the system (800) has a polymer resin composition(600) with a resin component (610) and an activation component (620).

In some embodiments, the structural repair and reinforcement system(800) is stored until installed by an end user.

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viacomposite technology includes preparing a substrate (700) forapplication via cleaning the substrate (700). In some embodiments, looseparticles, scale, surface oxidation, and oily films are removed viaphysical abrasion or power washing.

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viacomposite technology includes preparing a substrate (700) forapplication via priming the substrate (700) with a low-viscosity epoxyprimer (710). In some embodiments, the primer (710) is applied to thesubstrate (700) via a roller (720).

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viacomposite technology includes preparing the polymer resin composition(600) for application via combining the resin component (610) and theactivation component (620) in a specified ratio.

Wet Layup Option

In some embodiments, a wet layup method for maximizing tensile strengthand modulus of elasticity per ply in a reinforcement or repair operationvia composite technology includes preparing a substrate (700) forapplication via high pressure water or abrasion. In some embodiments, aprimer is applied to assist bond adhesion. In some embodiments, toassist installation, a tack or thickened paste is applied to assistinstallation. In some embodiments, the tack coat consists of the polymerresin composition (600). In some embodiments, the tack coat is appliedto the substrate (700) via the roller or trowel (720). In someembodiments, a method for maximizing tensile strength and modulus ofelasticity per ply in a reinforcement or repair operation via compositetechnology includes applying a saturating quantity of the resincomposition (600) to the surface of the reinforcement fabric (100). Insome embodiments, the resin composition (600) is applied to thesubstrate (700) via the roller (720). In some embodiments, the resincomposition (600) is applied to the reinforcement fabric (100) via asaturation machine. In some embodiments, a method for maximizing tensilestrength and modulus of elasticity per ply in a reinforcement or repairoperation via composite technology includes laying a ply ofreinforcement fabric (100) on the prepared substrate (700). In someembodiments, the ply of reinforcement fabric (100) is laid in adirection wherein the pocket (300) direction linearly traverses the hoopdirection of a pipe or other substrate.

Dry Layup Option

In some embodiments, a dry layup method for maximizing tensile strengthand modulus of elasticity per ply in a reinforcement or repair operationvia composite technology includes laying a ply of reinforcement fabric(100) on the prepared substrate (700). In some embodiments, the ply ofreinforcement fabric (100) is laid in a direction wherein the pocket(300) direction linearly traverses the hoop direction of a pipe or othersubstrate.

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viacomposite technology includes distributing the resin composition (600)through an open area (740) of the reinforcement fabric (100) until thereinforcement fabric (100) is saturated by the resin composition (600).In some embodiments, the resin composition (600) is distributed throughthe open area (740) of the reinforcement fabric (100) via the roller(720).

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viacomposite technology includes repeating the process of laying the fabric(100), applying the resin composition (600), and distributing the resincomposition (600) until a desired thickness of the structural repair andreinforcement system (800) is reached. In some embodiments, one or moreplys of reinforcement fabric (100) can be laid on a prepared substrate(700). In some embodiments, a ply is a single layer of the reinforcementfabric (100).

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viacomposite technology includes applying a finish coat of resincomposition (600) to an exterior surface of the laid fabric (100). Insome embodiments, the finish coat is applied to the exterior surface ofthe laid fabric (100) via the roller (720).

Structural Repair and Reinforcement Method Via Preimpregnated CompositeTechnology

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viapreimpregnated composite technology includes obtaining a structuralrepair and reinforcement system (810).

In some embodiments, the system (810) has a ply of reinforcement fabric(100) having a first fabric edge seam (210) located on a first fabricedge (220), and a second fabric edge seam (230) located on a secondfabric edge (240). In some embodiments, the first fabric edge seam (210)traverses and binds the fabric (100) parallel and adjacent to the firstfabric edge (220), and the second fabric edge seam (230) traverses andbinds the fabric (100) parallel to and adjacent to the second fabricedge (240). In some embodiments, the first fabric edge (220) and secondfabric edge (240) traverse the fabric (100) in the direction of anX-axis (0 degrees) (500).

In some embodiments, the fabric (100) has a pocket (300) with a firstpocket edge (320), a second pocket edge (340), a pocket front surface(350), and a pocket rear surface (360). In some embodiments, the pocket(300) has a first pocket seam (310) located on the first pocket edge(320). In some embodiments, the first pocket seam (310) has a stitching(370) in a plane defined by the X-axis (0 degrees) (500) and a Z-axis(520) alternatingly attaching the pocket front surface (350) to thepocket rear surface (360) via the stitching (370). In some embodiments,the first pocket seam (310) traverses the fabric (100) parallel andadjacent to the first pocket edge (320).

In some embodiments, the pocket (300) has a second pocket seam (330)located on the second pocket edge (340). In some embodiments, the secondpocket seam (330) has a stitching (370) in a plane defined by the X-axis(0 degrees) (500) and the Z-axis (520) alternatingly attaching thepocket front surface (350) to the pocket rear surface (360) via thestitching (370). In some embodiments, the second pocket seam (330)traverses the fabric (100) parallel and adjacent to the second pocketedge (340).

In some embodiments, the pocket front surface (350) has a pocketcross-stitch (380) that perpendicularly traverses the pocket (300) withrespect to the first pocket seam (310) and the second pocket seam (330)in a direction of a Y-axis or 90 degrees (510). In some embodiments, thepocket rear surface (360) has a pocket cross-stitch (380) thatperpendicularly traverses the pocket (300) with respect to the firstpocket seam (310) and the second pocket seam (330) in the direction ofthe Y-axis or 90 degrees (510).

In some embodiments, the pocket cross-stitch (380) has a stitch firstend (382) attached to the first pocket seam (310) and a stitch secondend (384) attached to the second pocket seam (330).

In some embodiments, the pocket (300) traverses the fabric (100)parallel and adjacent to the first fabric edge (220) and the secondfabric edge (240) in a warp, or 0 degree, or X-axis (500) direction.

In some embodiments, the fabric (100) has a fiber tow (400) with aplurality of filaments (410) located in a stack (420). In someembodiments, the fiber tow (400) is located lengthways in the directionof the X-axis (0 degrees) (500) in the pocket (300).

In some embodiments, the filament (410) is constructed from a materialselected from a group consisting of: polyethylene, glass, basalt,aramid, and carbon.

In some embodiments, a modified vinyl ester resin composition (630) islocated on the reinforcement fabric (100). In some embodiments, themodified vinyl ester resin composition (630) is cross-linked withurethane. In some embodiments, the modified vinyl ester resincomposition (630) is cross-linked with another compound. In someembodiments, a modified vinyl ester resin composition is available asDION® 31038-00 that can be purchased from Reichhold(http://www.reichhold.com/en/composites-products.aspx?cat=Brands&pid=14)as of Dec. 21, 2011.

In some embodiments, the system (810) is stored until installed by anend user. In some embodiments, the system (810) has a shelf life of sixmonths. In some embodiments, the system (810) can be stored in anenvironment having temperatures about ambient. In some embodiments,ambient temperature is less than about 60 degrees Fahrenheit. In someembodiments ambient temperature is about 60 degrees Fahrenheit to about80 degrees Fahrenheit. In some embodiments, ambient temperature is about8 In some embodiments, the system (810) has air-tight packaging (730).

In some embodiments, the system (810) is heat-activated. In someembodiments, the system (810) is activated for curing upon raising thetemperature of the system (810) to about 275 degrees Fahrenheit forabout 15 minutes. In some embodiments, the system (810) is activatedupon exposure to water.

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viapreimpregnated composite technology includes preparing a substrate (700)for application via cleaning the substrate (700). In some embodiments,loose particles, scale, surface oxidation, and oily films are removedvia physical abrasion or power washing.

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viapreimpregnated composite technology includes preparing a substrate (700)for application via priming the substrate (700) with a low-viscosityepoxy primer (710). In some embodiments, the primer is applied to thesubstrate (700) via a roller (720).

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viapreimpregnated composite technology includes opening the air-tightpackaging (730) and removing the reinforcement fabric (100) for use.

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viapreimpregnated composite technology includes laying a ply ofreinforcement fabric (100) on the prepared substrate (700). In someembodiments, the ply of reinforcement fabric (100) is laid in adirection wherein the pocket (300) linearly traverses the hoop directionof a pipe or other substrate.

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viapreimpregnated composite technology includes compressing thereinforcement fabric (100) until the reinforcement fabric (100) issaturated by the resin composition (630). In some embodiments, the resincomposition (630) is distributed through the open area (740) of thereinforcement fabric (100) via the roller (720).

In some embodiments, a method for maximizing tensile strength andmodulus of elasticity per ply in a reinforcement or repair operation viapreimpregnated composite technology includes repeating the process oflaying the fabric (100), and distributing the resin composition (630)until the desired thickness of the preimpregnated structural repair andreinforcement system (810) is reached. In some embodiments, one or moreplys of reinforcement fabric (100) can be laid on a prepared substrate(700). In some embodiments, a ply is a single layer of the reinforcementfabric (100).

In some embodiments, a reinforcement fiber housing matrix (900) formaximizing tensile strength and modulus of elasticity per ply forcomposite systems, the housing matrix (900) has a channel (910) with afirst channel side (920), and a second channel side (930); and a fibertow (400) with a plurality of filaments (410) located in a stack (420).

In some embodiments, the fiber tow (400) is located lengthways in thedirection of the X-axis (0 degrees) (500) in the channel (910). In someembodiments, the channel (910) traverses the matrix parallel andadjacent to the first channel side (920) and the second channel side(930) in a warp, or 0 degree, or X-axis direction.

In some embodiments, a plurality of channels (910) is located inparallel in a series, with the first channel side (920) of a firstchannel (910) joined to a second channel side (930) of a second channel(910). In some embodiments, a plurality of channels (910) is joined inparallel in a series at the first channel side (920) and the secondchannel side (930) of each channel (910) in the series.

In some embodiments, the channel (910) has a cross-sectional shape of apolygon, for example, a triangle, a square, a rectangle, a hexagon or anoctagon. In some embodiments, the channel (910) has a cross-sectionalshape of an ellipse or a circle.

In some embodiments, a sub-channel (950) is located within the channel.In some embodiments, the sub-channel (950) is supported within thechannel (910) via a structure. In some embodiments, the sub-channel(950) is a partitioned area of the channel (910).

In some embodiments, the sub-channel (950) has a cross-sectional shapeof a polygon, for example, a triangle, a square, a rectangle, a hexagonor an octagon. In some embodiments, the sub-channel (950) has across-sectional shape of an ellipse or a circle.

In some embodiments, a polymer resin composition (600) is located in thesub-channel (950). In some embodiments, a corrosion resistant polymerresin composition (600) is located in the sub-channel (950). In someembodiments, a corrosion resistant compound is located in thesub-channel (950). In some embodiments, corrosion resistant filaments(410) are located in the sub-channel (950).

In some embodiments, a chemically resistant polymer resin composition(600) is located in the sub-channel (950). In some embodiments, achemically resistant compound is located in the sub-channel (950). Insome embodiments, chemically resistant filaments (410) are located inthe sub-channel (950).

In some embodiments, a polymer resin composition (600) is located in thesub-channel (950), wherein the stack (420) is located in the channel(910). In some embodiments, a polymer resin composition (600) islocated, alternatingly in the sub-channel (950) and the channel (910).In some embodiments, the stack (420) is located alternatingly in thesub-channel (950) and the channel (910).

In some embodiments, the channel (910) is constructed from a permeablematerial. In some embodiments, the channel (910) is constructed from amesh material. In some embodiments, the channel (910) is constructedfrom a porous material. In some embodiments, the channel (910) isconstructed from a metal, for example, aluminum or steel.

In some embodiments, the sub-channel (950) is constructed from apermeable material. In some embodiments, the sub-channel (950) isconstructed from a mesh material. In some embodiments, the sub-channel(950) is constructed from a porous material. In some embodiments, thesub-channel (950) is constructed from a metal, for example, aluminum orsteel.

In some embodiments, the channel (910) is located in a weft, or 90degree, or Y-axis (510), direction with respect to the first channelside (920) and the second channel side (930).

In some embodiments, the fabric (100) is unidirectional, meaning greaterthan about 90% of the filaments (410) are oriented in a commondirection. In some embodiments, the fabric (100) is bi-directional,meaning about 50% of the filaments (410) are oriented in a firstdirection, with the other about 50% of the filaments (410) are orientedin a direction perpendicular to the first direction. In someembodiments, the fabric (100) is layered in the 3 dimensional or Z-axisdirection. In some embodiments, plys of the fabric (100) is rotationallyoriented in 45 degree increments.

In some embodiments, the cross-sectional area of the stacks (420) isabout 50% to 70% of the cross-sectional area of the channel (910). Insome embodiments, the cross-sectional area of the stacks (420) is about70% to 85% of the cross-sectional area of the channel (910). In someembodiments, the cross-sectional area of the stacks (420) is about 85%to 99.5% of the cross-sectional area of the channel (910).

In some embodiments, the volume of the stacks (420) in the channel (910)is about 50% to 70% of the volume of the channel (910). In someembodiments, the volume of the stacks (420) in the channel (910) isabout 70% to 85% of the volume of the channel (910). In someembodiments, the volume of the stacks (420) in the channel (910) isabout 85% to 99.5% of the volume of the channel (910).

As used herein, the term “about” refers to plus or minus 10% of thereferenced number. For example, an embodiment wherein there are about3000 filaments (410) includes between 2700 and 3300 filaments (410).

Various modifications of the invention, in addition to those describedherein, will be apparent to those skilled in the art from the foregoingdescription. Such modifications are also intended to fall within thescope of the appended claims. Each reference cited in the presentapplication is incorporated herein by reference in its entirety.

Although there has been shown and described the preferred embodiment ofthe present invention, it will be readily apparent to those skilled inthe art that modifications may be made thereto which do not exceed thescope of the appended claims. Therefore, the scope of the invention isonly to be limited by the following claims.

The reference numbers recited in the below claims are solely for ease ofexamination of this patent application, and are exemplary, and are notintended in any way to limit the scope of the claims to the particularfeatures having the corresponding reference numbers in the drawings.

What is claimed is:
 1. A novel reinforcement fabric (100) system for maximizing tensile strength and modulus of elasticity per ply for composite systems comprising: (a) a first fabric edge seam (210) disposed on a first fabric edge (220) and a second fabric edge seam (230) disposed on a second fabric edge (240), said first fabric edge seam (210) traverses and binds the fabric (100) parallel and adjacent to the first fabric edge (220), said second fabric edge seam (230) traverses and binds the fabric (100) parallel to and adjacent to the second fabric edge (240), said first fabric edge (220) and second fabric edge (240) traverse the fabric (100) in the direction of an X-axis (0 degrees) (500); (b) a pocket (300) comprising a first pocket edge (320), a second pocket edge (340), a pocket front surface (350), and a pocket rear surface (360); said pocket comprising the pocket (300) has a first pocket seam (310) disposed on the first pocket edge (320), said first pocket seam (310) comprising a stitching (370) in a plane defined by the X-axis (0 degree) (500) and a Z-axis (520) alternatingly attaching the pocket front surface (350) to the pocket rear surface (360) via the stitching (370), said first pocket seam (310) traverses the fabric (100) parallel and adjacent to the first pocket edge (320), said pocket (300) comprising a second pocket seam (330) disposed on the second pocket edge (340), said second pocket seam (330) comprising a stitching (370) in a plane defined by the X-axis (0 degree) (500) and a Z-axis (520) alternatingly attaching the pocket front surface (350) to the pocket rear surface (360) via the stitching (370), said second pocket seam (330) traverses the fabric (100) parallel and adjacent to the second pocket edge (340), said pocket front surface (350) comprises a pocket cross-stitch (380), said pocket cross-stitch (380) perpendicularly traverses the pocket (300) with respect to the first pocket seam (310) and the second pocket seam (330) in a direction of a Y-axis or 90 degrees (510), said pocket rear surface (360) comprises a pocket cross-stitch (380), said pocket cross-stitch (380) perpendicularly traverses the pocket (300) with respect to the first pocket seam (310) and the second pocket seam (330) in a direction of a Y-axis or 90 degrees (510); and (c) a fiber tow (400) comprising a plurality of filaments (410) disposed in a stack (420), wherein the fiber tow (400) is disposed lengthways in the direction of the X-axis (0 degrees) (500) in the pocket (300); wherein the pocket front surface (350) has a pocket cross-stitch (380) disposed thereon, wherein the pocket cross-stitch (380) perpendicularly traverses the pocket (300) from the first pocket edge (320) to the second pocket edge (340) without penetrating through the fiber tow (400), and wherein the pocket rear surface (360) has a pocket cross-stitch (380) disposed thereon, wherein the pocket cross-stitch (380) perpendicularly traverses the pocket (300) from the first pocket edge (320) to the second pocket edge (340) without penetrating through the fiber tow (400).
 2. The fabric (100) of claim 1, further comprising a plurality of pockets (300) joined in parallel in a series at a first pocket edge (320) and a second pocket edge (340) of each pocket (300) in the series.
 3. The fabric (100) of claim 1, wherein the filament (410) is constructed from a material selected from a group consisting of: polyethylene, glass, basalt, aramid, and carbon.
 4. The fabric (100) of claim 1, wherein the fiber tow (400) comprises from about 1 filament (410) to about 3,000 filaments (410).
 5. The fabric (100) of claim 1, wherein the fiber tow (400) comprises from about 3,000 filaments (410) to about 6,000 filaments (410).
 6. The fabric (100) of claim 1, wherein the fiber tow (400) comprises from about 6,000 filaments (410) to about 12,000 filaments (410).
 7. The fabric (100) of claim 1, wherein the fiber tow (400) comprises from about 12,000 filaments (410) to about 50,000 filaments (410).
 8. The fabric (100) of claim 1, wherein the fiber tow (400) comprises more than about 50,000 filaments (410).
 9. The fabric (100) of claim 1, wherein the fiber tow (400) comprises a plurality of non-interlaced filaments (410).
 10. The fabric (100) of claim 1, wherein the fiber tow (400) comprises a plurality of interlaced filaments (410).
 11. The fabric (100) of claim 1, wherein the fiber tow (400) comprises a plurality of non-twisted filaments (410).
 12. The fabric (100) of claim 1, wherein the fiber tow (400) comprises a plurality of twisted filaments (410).
 13. The fabric (100) of claim 1, wherein the fiber tow (400) comprises a plurality of filaments (410) disposed one upon another forming a generally elliptical cross-section of the fiber tow (400) disposed in the pocket (300).
 14. A structural repair and reinforcement system (800) for maximizing tensile strength and modulus of elasticity per ply via composite technology comprising a ply of the reinforcement fabric (100) according to claim 1, and a polymer resin composition (600).
 15. A novel reinforcement fabric (100) system for maximizing tensile strength and modulus of elasticity per ply for composite systems comprising: (a) a first fabric edge seam (210) disposed on a first fabric edge (220) and a second fabric edge seam (230) disposed on a second fabric edge (240), said first fabric edge seam (210) traverses and binds the fabric (100) parallel and adjacent to the first fabric edge (220), said second fabric edge seam (230) traverses and binds the fabric (100) parallel to and adjacent to the second fabric edge (240), said first fabric edge (220) and second fabric edge (240) traverse the fabric (100) in the direction of an X-axis (0 degrees) (500); (b) a pocket (300) comprising a first pocket edge (320), a second pocket edge (340), a pocket front surface (350), and a pocket rear surface (360), said pocket comprising the pocket (300) has a first pocket seam (310) disposed on the first pocket edge (320), said first pocket seam (310) comprising a stitching (370) in a plane defined by the X-axis (0 degree) (500) and a Z-axis (520) alternatingly attaching the pocket front surface (350) to the pocket rear surface (360) via the stitching (370), said first pocket seam (310) traverses the fabric (100) parallel and adjacent to the first pocket edge (320), said pocket (300) comprising a second pocket seam (330) disposed on the second pocket edge (340), said second pocket seam (330) comprising a stitching (370) in a plane defined by the X-axis (0 degree) (500) and a Z-axis (520) alternatingly attaching the pocket front surface (350) to the pocket rear surface (360) via the stitching (370), said second pocket seam (330) traverses the fabric (100) parallel and adjacent to the second pocket edge (340), said pocket front surface (350) comprises a pocket cross-stitch (380), said pocket cross-stitch (380) perpendicularly traverses the pocket (300) with respect to the first pocket seam (310) and the second pocket seam (330) in a direction of a Y-axis or 90 degrees (510), said pocket rear surface (360) comprises a pocket cross-stitch (380), said pocket cross-stitch (380) perpendicularly traverses the pocket (300) with respect to the first pocket seam (310) and the second pocket seam (330) in a direction of a Y-axis or 90 degrees (510), wherein said pocket (300) traverses the fabric (100) parallel and adjacent to the first fabric edge (220) and the second fabric edge (240) in the direction of the X-axis (500); and (c) a fiber tow (400) comprising a plurality of filaments (410) disposed in a stack (420), wherein the fiber tow (400) is disposed lengthways in the direction of the X-axis (0 degrees) (500) in the pocket (300); wherein the pocket front surface (350) has a plurality of pocket cross-stitches (380) disposed thereon, each pocket cross-stitch (380) perpendicularly traversing the pocket (300) from the first pocket edge (320) to the second pocket edge (340) without penetrating through the fiber tow (400), and wherein the pocket rear surface (360) has a plurality of pocket cross-stitches (380) disposed thereon, each pocket cross-stitch (380) perpendicularly traversing the pocket (300) from the first pocket edge (320) to the second pocket edge (340) without penetrating through the fiber tow (400). 